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Life Fitness 8500 Service Manual

Total body cross-trainers with rear drive system
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Manual - 41 pages
Operation manual - 36 pages
User manual - 34 pages

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Models 8500, 9100, and 9500HR
Total Body Cross-Trainers with Rear Drive System
Customer Support Services
SERVICE MANUAL

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  Summary of Contents for Life Fitness 8500

  • Page 1 Models 8500, 9100, and 9500HR Total Body Cross-Trainers with Rear Drive System Customer Support Services SERVICE MANUAL...
  • Page 2 Via telefacsimile - 24 hrs. /day, 7 days/week. Via telephone - Monday through Friday from 8:00 AM to 7:00 PM ( C.S.T.). To speed Life Fitness Customer Support Services response to your needs, please be prepared to provide the following information to the phone technician.
  • Page 3: Electronic System

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers THEORY OF OPERATION The electronic system on the rear-drive crosstrainer is made up of three main functional blocks: 1) Console, 2) HR telemetry, and 3) Alternator, Power Control Board, and Load. In addition, the 9500 model has Lifepulse contact HR.
  • Page 4 Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TERMINOLOGY The following words and acronyms are commonly referred to throughout this manual. Take time to familiarize yourself with them. Connectors Electrical plugs used to connect wiring into electrical component. Display Console Electronic board for making settings and monitoring physical output.
  • Page 5: Table Of Contents

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TABLE OF CONTENTS SECTION I TROUBLESHOOTING GUIDES PAGE GRINDING, RUBBING, KNOCKING NOISE..............2 DRIVE BELT SLIPPING ....................3 UPPER ARMS LOOSE....................3 PLAY IN PEDAL LEVER....................3 NO LOAD ........................3 NO LEDS ON DISPLAY ....................3 ALTERNATOR BELT SLIPPING..................
  • Page 6: Table Of Contents – Continued

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TABLE OF CONTENTS – Continued SECTION III HOW TO...REPLACE THE: DISPLAY CONSOLE ....................2 ACCESSORY TRAY (OPTIONAL ON CT8500) ..............3 DISPLAY CONSOLE SUPPORT ASSEMBLY ..............4 REAR COVERS ......................5 CRANKARM ROLLER ASSEMBLY AND COVER ............6 CRANKARM ASSEMBLY .....................
  • Page 7 Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TABLE OF CONTENTS – Continued SECTION V PARTS IDENTIFICATION MODEL IDENTIFICATION and SERIAL NUMBER LOCATION ........... 2 CT 8500........................3 CT 9100........................5 CT 9500 - 15 ........................ 7 CT 9500 - 17 ........................ 9 NOTES........................
  • Page 8 © 2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. Life Fitness, Lifecycle, and Lifepulse are registered trademarks, and Heart Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar Electro, Inc.
  • Page 9: Section I

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers SECTION I TROUBLESHOOTING GUIDES...
  • Page 10: Grinding, Rubbing, Knocking Noise

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers Malfunction Probable Cause Corrective Action Grinding, rubbing, knocking noises Pulleys misaligned. Loosen the pillow block bearings, when pedal levers rotate under realign the pulleys, and retighten the load. pillow block bearings. Dirt build up in pedal tracks.
  • Page 11 Link mounting loose. Clean, lubricate, and retighten.
  • Page 12: Drive Belt Slipping

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers Malfunction Probable Cause Corrective Action Grinding, rubbing, knocking noises Excessive end play in rocker arms. Adjust collars as necessary to take when pedal levers rotate under out the end play. See How To load.
  • Page 13 Faulty power control board. Using a voltmeter, verify 8Vdc at 11 position connector pin 4 on the power control board. If present, replace console cable. If not, replace board.
  • Page 14: Alternator Belt Slipping

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers Malfunction Probable Cause Corrective Action Alternator belt slipping. Belt is loose. Retension from 65-70 lb. No heart rate or erratic heart rate. Pinched cable in Monocolumn cover. Remove monocolumn covers and inspect cables. Replace damaged cable.
  • Page 16: No Leds Or Random Leds Lit

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers Malfunction Probable Cause Corrective Action No LEDs or random LEDs lit. Cable connection faulty. Remove display console and verify cable is properly plugged into console. Main wire harness damaged. Check for a damaged wire harness.
  • Page 17: Notes

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers NOTES:...
  • Page 18: Diagnostic Modes

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers SECTION II DIAGNOSTIC MODES...
  • Page 19: Display Consoles

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers CT8500, CT9100, and CT9500HR Display Consoles The following three(3) Display Consoles are representative for each model crosstrainer. The following Diagnostic State pages depict a CT9100 Display Console. Regardless of Display Console, the Message Center always provides current Diagnostic Data.
  • Page 20: Entering Diagnostic States 1-17

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers ENTERING DIAGNOSTIC STATES 1-17 To enter the diagnostic mode, proceed as follows: 1. Press down and hold the DOWN ARROW key. While doing this, press the CLEAR (CT9100) or CLEAR/PAUSE (CT9500) key twice within 2.5 seconds. The console will go blank momentarily, but do not release the DOWN ARROW key.
  • Page 21: Diagnostic State 1: Leds And Keypad Test

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 1 - LEDs and KEYPAD TEST Level Heart Rate Cal/Hour Time Calories Distance Watts Message ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Center Lock Lock...
  • Page 22: Diagnostic State 2: Individual Led Test

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 2 - INDIVIDUAL LED TEST Level Heart Rate Cal/Hour Time Calories Distance Watts ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170 153 145...
  • Page 23 NOTE: Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10% (CT9100/8500 feature). Use 4 and 6 KEYS to increment and decrement LDC value by 10% (CT9500 feature). Press the CLEAR key to return to Diagnostics State 2.
  • Page 24: (Display Lock Equipped Model Only)

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 3 - Code Version and RPM, Networking, and LDC Tests (DISPLAY LOCK EQUIPPED MODEL ONLY) Level Heart Rate Cal/Hour Time Calories Distance Watts 1 2 3 ® Clear Pause 162 153...
  • Page 26: Diagnostic State 4 - Field/Alternator-Regulator Test

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 4 - FIELD/ALTERNATOR-REGULATOR TEST Level Heart Rate Cal/Hour Time Calories Distance Watts FIELD/ALTREG TST ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 27: Diagnostic State 5: Program Version And Networking Test

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 5 - PROGRAM VERSION AND NETWORKING TEST Level Heart Rate Cal/Hour Time Calories Distance Watts PX.XX PX.XX NONE ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock...
  • Page 28: Diagnostic State 5: Lifepulse Test

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 5 – LIFEPULSE TEST (DISPLAY LOCK EQUIPPED MODEL ONLY) Level Heart Rate Cal/Hour Time Calories Distance Watts 1 2 3 ® Clear Pause 162 153 4 5 6 Quick 128 119...
  • Page 29: Diagnostic State 6: Maximum Workout Duration

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 6 - MAXIMUM WORKOUT DURATION Level Heart Rate Cal/Hour Time Calories Distance Watts MAX DURATION 60 ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock...
  • Page 30: Diagnostic State 7: Telemetry On/Off

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 7 - TELEMETRY ON/OFF Level Heart Rate Cal/Hour Time Calories Distance Watts TELEMETRY ON ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 31: Diagnostic State 8: English / Metric Units

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 8 - ENGLISH OR METRIC UNITS Level Heart Rate Cal/Hour Time Calories Distance Watts ENGLISH UNITS ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock...
  • Page 32: Diagnostic State 9: Power Supply Type

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 9 - POWER SUPPLY TYPE Level Heart Rate Cal/Hour Time Calories Distance Watts BATTERY ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 33: Diagnostic State 10: Shutdown Time

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 10 - SHUTDOWN TIME Level Heart Rate Cal/Hour Time Calories Distance Watts SHUTDOWN TIME 60 ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 34: Diagnostic State 11: Program Time

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 11 - PROGRAM TIME Level Heart Rate Cal/Hour Time Calories Distance Watts PROGRAM TIME 60 ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 35: Diagnostic State 12: Statistics

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 12 – STATISTICS Level Heart Rate Cal/Hour Time Calories Distance Watts STATISTICS ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170 153 145...
  • Page 36: Diagnostic State 13 - Mets Enable/Disable

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 13 - METS ENABLE/DISABLE Level Heart Rate Cal/Hour Time Calories Distance Watts METS OFF ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 37: Diagnostic State 14: Keypad Selection

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 14 - KEYPAD SELECTION Level Heart Rate Cal/Hour Time Calories Distance Watts CT91/55 K-PAD ON ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 38: Diagnostic State 15 - Toggle Enable/Disable

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 15 - TOGGLE ENABLE/DISABLE Level Heart Rate Cal/Hour Time Calories Distance Watts TOGGLED DISABLED ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170...
  • Page 39: Diagnostic State 16: Photoshoot

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 16 – PHOTOSHOOT Level Heart Rate Cal/Hour Time Calories Distance Watts 28:45 ¨ ® Display Display Display Clear Pause Clear Clear Pause Pause Lock Lock Lock 179 170 153 145...
  • Page 40: Diagnostic State 16: Lanquage Configuration

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 16 – LANGUAGE CONFIGURATION (DISPLAY LOCK EQUIPPED MODEL ONLY) Level Heart Rate Cal/Hour Time Calories Distance Watts 1 2 3 ® Clear Pause 162 153 4 5 6 145 136...
  • Page 41: Diagnostic State 17: Photoshoot

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers DIAGNOSTIC STATE 17 – PHOTOSHOOT (DISPLAY LOCK EQUIPPED MODEL ONLY) Level Heart Rate Cal/Hour Time Calories Distance Watts 28:45 52 1 2 3 ® Clear Pause 162 153 4 5 6 145 136...
  • Page 42 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers NOTES:...
  • Page 43 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers SECTION III “How To...” SERVICE AND REPAIR GUIDE...
  • Page 44 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace the Display Console Tools required: Phillips screwdriver 1. Remove the MOUNTING SCREWS(4) from under 3-Pin the CONSOLE. Connector Console 2. Lift the console up enough to disconnect the 10-Pin and 3 or 4-Pin connectors.
  • Page 45: Accessory Tray (Optional On Ct8500)

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace the Accessory Tray (Optional on CT8500) Tools required: Phillips screwdriver, Allen wrench set, and 3/8” Standard wrench set 1. Remove the MOUNTING SCREWS(4) from Accessory under the CONSOLE. Tray 3-Pin 2.
  • Page 46 Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers How To... Replace the Display Console Support Assembly Tools required: Phillips screwdriver and Allen wrench set Rocker Cover and Screws(3) Back Polar Rocker Receiver Cover Polar Foam Insulator Receiver Monocolumn Monocolumn Foam Insulator...
  • Page 47 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Rear Covers Tools required: Phillips magnetic screwdriver #2, Allen wrench set, 3/8” Socket set, and Standard wrench set 1. Remove the OUTER LINK COVER Pedal Lever Nuts(2) by removing six(6) mounting Torque 30-35 FT.
  • Page 48 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Crankarm Roller Assembly and Cover Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver 1. Remove the REAR COVERS. See How To… Remove Rear Covers.
  • Page 49: Rear Covers

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Crankarm Assembly Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver 1. Remove the REAR COVERS. See How To… Remove Crankarm Cover Rear Covers. Roller Bearing Assembly 2.
  • Page 50: Alternator

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Drive Belt and Alternator Belt Tools required: 3/8” Socket set and Standard wrench set, and Phillips screwdriver Alternator Belt New: 75-85 lbs Used: 60 lbs Main Drive Belt...
  • Page 51 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To...Remove Power Control Board Assembly Tools Required: Slotted head screwdriver and Phillips screwdriver 1. Remove the right REAR COVER. See How To…Remove Rear Covers. 2. Disconnect the 12 and 11-Pin Connectors on the PCB.
  • Page 52 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To...Replace Alternator Tools Required: 3/8” Socket set and Standard wrench set, and Phillips screwdriver Alternator 1. Remove the REAR COVERS. See How Pivot Bolt To…Remove Rear Covers. Alternator Mounting Bolt 2. Disconnect the ALTERNATOR WIRING...
  • Page 53 Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers How To...Replace Alternator Belt Tools Required: 3/8” Socket set and Standard wrench set, and Phillips screwdriver 1. Remove the REAR COVERS. See How To…Remove Rear Covers. Alternator Mounting Rotate Bolt 2. Loosen the ALTERNATOR PIVOT Down BOLT and its MOUNTING BOLT.
  • Page 54: Pedal Lever Assembly

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Pedal Lever Assembly Tools required: Phillip screwdriver, Allen wrench set, 3/8” Socket set, and Standard wrench set 1. Remove six(6) screws from the OUTER LINK Pedal Lever Nuts(2) Torque 30-35 FT. LBS.
  • Page 55: Rocker Arms

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers How To... Replace Rocker Arms Tools required: 3/8 Socket set and Standard wrench set 1. Remove the UPPER ARMS. See How To…Replace User Arms. End Cap Torque 2. Remove the MONOCOLUMN COVERS and 30-35 FT.
  • Page 56: Tie Rod

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Tie Rod Tools required: Phillips magnetic screwdriver #2 and 3/8 Socket set 1. Remove the OUTER LINK COVER by removing the six(6) mounting screws. Clevis Covers 2. Remove the TIE ROD NUT from the ARM EXTENSION and PEDAL ARM.
  • Page 57: Crankshaft Pulley Assembly

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Crankshaft Pulley Assembly Tools required: Allen wrench set, 3/8” Socket set, and Standard wrench set Crankshaft Crankshaft 1. Remove the REAR COVERS. Plate Washer Pulley See How To…Remove Rear Covers.
  • Page 58: Intermediate Pulley

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Intermediate Pulley Tools required: 3/8” Socket set and Standard wrench set 1. Remove the REAR COVERS. See How Alternator To…Remove Rear Covers. Pivot Bolt Rotate Down Alternator 2. Loosen the ALTERNATOR PIVOT BOLT and...
  • Page 59: Load Resistors

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Load Resistors Tools required: Slotted screwdriver 1. Remove the right REAR COVER. See How To…Remove Rear Covers. 2. Disconnect wires at the LOAD RESISTORS. 3. Remove the LOAD RESISTORS...
  • Page 60: User Arms

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The User Arms Tools required: Allen wrench set and Phillips screwdriver 1. MODELS 8500 and 9100: Raise the BOOT COVERS on the UPPER ARMS. MODEL 9500: Remove four(4) mounting bolts from the USER ARM REAR COVERS and remove these covers.
  • Page 61: Polar Receiver

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Polar Receiver Tools required: Phillips screwdriver Monocolumn 1. MODELS 8500 / 9100: Remove four(4) Front Cover mounting bolts from the two halves of the MONOCOLUMN COVER and separate.
  • Page 62 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Monocolumn Cover Tools required: Phillips screwdriver Monocolumn 1. MODELS 8500 / 9100: Remove four(4) Front Cover mounting bolts from the two halves of the MONOCOLUMN COVER and separate. 2. MODEL 9500: Remove four(4) mounting bolts from each USER ARM REAR COVER(2).
  • Page 63: Frame Cover

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Frame Cover Tools required: Phillips screwdriver, Standard screwdriver, Allen wrench set, 3/8” Socket set, and Wrenches 1. Remove the REAR COVERS. See How To…Remove Rear Covers. 2. Remove the FRONT COVER.
  • Page 64: Front Cover

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Front Cover Tools required: Phillips magnetic screwdriver #2 1. Remove the FRONT COVER screws(6) and separate the front cover halves. 2. Install new front cover in reverse order.
  • Page 65: Battery

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Battery Tools required: Phillips magnetic screwdriver #2 1. Remove the FRONT COVER screws(6) and separate the front cover halves. Battery 2. Disconnect the BATTERY CABLES. Battery Cables 3. Remove the battery mounting screws(2) and lift out the BATTERY.
  • Page 66: Rear Wheels And Axle

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Rear Wheels and Axle Tools required: Slotted screwdriver and Pliers 1. Remove the AXLE CAP from the WHEEL AXLE. 2. Remove the WHEELS and AXLE. 3. Install new wheels, axle, and axle cap in the reverse direction.
  • Page 67: Endcaps

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace The Endcaps Tools required: Slotted screwdriver 1. Remove the endcaps from the LOWER ARMS. Endcap 2. Remove the endcaps from the FRAME. 3. Install new endcaps in reverse order.
  • Page 68: Pedal

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Replace Pedal Tools required: Clean cloth, water, and isopropyl alcohol 1. Remove the pedals from the pedal arm assemblies. 2. Remove old tape. Pedal 3. Using a clean cloth, carefully clean the surface...
  • Page 69: Set Jumpers On Csafe Card

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers How To... Set Jumpers on CSAFE Card Tools required: Phillips screwdriver Front Cover 1. Remove six(6) screws from the FRONT COVER and separate the front cover halves. Frame, Bottom 2. Set jumpers according to chart below.
  • Page 70: Notes

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers NOTES:...
  • Page 71 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers SECTION IV ELECTRONICS OVERVIEW WIRING BLOCK DIAGRAMS...
  • Page 72 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD Connector P5 (Not applicable on Functional Description: 9500 with Display Lock only) The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the keypad input for...
  • Page 73 Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD – Continued Connector Location Functional Description P5 is an 8 pin connector that HR-ENABLE (3.8 VDC) connects the Life Pulse Board to the Console Board VSYS (7-8 VDC)
  • Page 74: Power Control Board

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers ELECTRONICS OVERVIEW - POWER CONTROL BOARD Functional Description: The Power Control Board is designed to regulate the alternator voltage by modulating the field current. It regulates the pass current (RPM signal) from the...
  • Page 75: Alternator

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers ELECTRONICS OVERVIEW – ALTERNATOR Functional Description: The 12 volt, 35 amp Alternator is designed to provide electrical power to the product, supply load resistance while providing electrical power, and provide the RPM signal from the AC TAP to the Alternator Control Board.
  • Page 76: Wiring Block Diagram

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers WIRING BLOCK DIAGRAM FOR LC9500HR...
  • Page 77: Notes

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers NOTES:...
  • Page 78: Section V

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers SECTION V PARTS IDENTIFICATION...
  • Page 79: Model Identification And Serial Number Location

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Model / Serial number...
  • Page 80 Life Fitness Model 8500 Cross-Trainer MODEL CT85-0100-01 SN 100000-Up Console Post Assembly Console AK61-00500-0005 AK61-00026-0001 Eng/Met Decal Overlay 0K61-01200-0000 Grips(2) AK61-00025-0001 Eng/Met 0K61-06003-0000 Main Cable AK61-00015-0000 Console Spacer Upper Arm (RT) 0K61-05009-0000 AK61-00460-0002 Boot(2) Upper Arm (LT) 0K61-06000-0000 AK61-00460-0003 Front Post Cover...
  • Page 81 Life Fitness Model 8500 Cross-Trainer MODEL CT85-0100-01 SN 100000-Up Tie Rod (2) GK61-00002-0020 Bolt Arm Extension 0017-00101-1646 0K61-03004-0000 0017-00103-0137 Bolt Sleeve 0017-00101-1645 0K61-01076-0000 Pedal (2) GK61-00002-0010 Tape (4) 0K61-04115-0002 Anit Lift Bracket (2) 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller Kit GK61-00002-0027...
  • Page 82 Life Fitness Model 9100 Cross-Trainer MODEL CT91-0100-01 SN 100000-Up Console Post Assembly AK61-00500-0004 Console- AK61-00024-0001 Eng/Met Decal Overlay - AK61-00023-0001 Eng/Met Main Cable - AK61-00015-0000 0K61-01200-0000 Polar Cable - AK61-00014-0000 Console Spacer - 0K61-05009-0000 Grips(2) Accessory Tray - GK61-00002-0002 0K61-06003-0000...
  • Page 83 Life Fitness Model 9100 Cross-Trainer MODEL CT91-0100-01 SN 100000-Up Tie Rod (2) GK61-00002-0020 Arm Extension Bolt 0K61-03004-0000 0017-00101-1646 Bolt 0017-00103-0137 0017-00101-1645 Sleeve 0K61-01076-0000 Pedal (2) GK61-00002-0010 Anti Lift Bracket (2) Tape (4) 0K61-04114-0000 0K61-04115-0002 Bolts (4) 0017-00101-1645 Roller Kit GK61-00002-0027...
  • Page 84 Life Fitness Model 9500 Cross-Trainers MODEL CT95-0100-15 SN 100000-Up Polar Cable - AK61-00014-0000 Console Post Assembly Main Cable - AK61-00015-0000 AK61-00500-0004 Overlay - AK61-00054-0001 Eng/Met Decal Console- AK61-00053-0001 Eng/Met 0K61-01200-0000 HR Cable - AK61-00052-0002 Accessory Tray - GK61-00002-0002 Upper Arm...
  • Page 85 Life Fitness Model 9500 Cross-Trainers MODEL CT95-0100-15 SN 100000-Up Tie Rod (2) Arm Extension GK61-00002-0020 0K61-03004-0000 Bolt Bolt 0017-00101-1645 0017-00101-1646 0017-00103-0137 Sleeve 0K61-01076-0000 Pedal (2) GK61-00002-0010 Anti Lift Bracket (2) Tape (4) 0K61-04114-0000 0K61-04115-0002 Bolts (4) 0017-00101-1645 Roller (2) 0K61-00002-0027...
  • Page 86 Life Fitness Model 9500 Cross-Trainers MODEL CT95-0100-17 SN 103198-Up Polar Cable AK61-00014-0000 Main Cable AK61-00015-0000 Overlay Console Post Assembly AK61-00076-0001 Eng/Met AK61-00500-0010 Console Decal AK61-00075-0001 Eng/Met 0K61-01200-0000 HR Cable AK61-00052-0002 Accessory Tray GK61-00002-0018 Upper Arm (RT) AK61-00048-00012 Front Post Cover...
  • Page 87 Life Fitness Model 9500 Cross-Trainers MODEL CT95-0100-17 SN 103198-Up Tie Rod (2) GK61-00002-0020 Bolt Arm Extension 0017-00101-1646 0K61-03004-0000 Bolt 0017-00103-0137 Sleeve 0017-00101-1645 0K61-01076-0000 Pedal (2) GK61-00002-0010 Tape (4) Anti Lift Bracket (2) 0K61-04115-0002 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller Kit Drive Pulley Assembly...
  • Page 88: Notes

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers NOTES:...
  • Page 89: Miscellaneous Information

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers SECTION VI MISCELLANEOUS INFORMATION...
  • Page 90: Preventive Maintenance Tips

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers PREVENTIVE MAINTENANCE TIPS Preventive Maintenance Schedule DAILY MONTHLY BI-ANNUALLY Housing Inside Clean Outside Clean Power Control Heatsink Clean Connectors Inspect Board Inspect Console Assembly Overlay Clean Mounting Bolts Inspect Connectors Inspect Alternator...
  • Page 91: Installation Instructions

    DO NOT operate your Cross-Trainer if it has been dropped, damaged, or even partially immersed in water. Contact Life Fitness Customer Support Services at the number in the Operation Manual. DO NOT locate the Cross-Trainer any closer than 30 inches ( 76 cm ) to a television set.
  • Page 92: Parts List

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers INSTALLATION INSTRUCTIONS ... Magnetic #2 Bit Phillips Screwdriver, 5/16” & 3/16” Hex Key OOLS EQUIRED FOR SSEMBLY Wrenches, 1/2" Open End Wrench Parts List Hex Socket Head Cap Screw Qty: 8 Phillips Pan Head Screw Qty: 4 3/8-16 x 1”...
  • Page 93 Step 1 Before proceeding, familiarize yourself with the parts of the Cross-Trainer and make sure that you have received all the items described in the Parts List. Step 2 Locate the left and right FRONT COVER (#9, #10). Using two PHILLIPS PAN HEAD SCREWS (#3), mount the USER LEFT FRONT COVER (#9) to the FRAME (A).
  • Page 94 Step 4 Detach and unwrap the WIRE HARNESS (E) (10P, 3P, (4P 9500HR Only)) located at the top of the MONOCOLUMN (F). Holding the CONSOLE SUPPORT ASSEMBLY (#7) with the handgrips facing upward, feed the WIRE HARNESS up through the neck and out the top access hole. Carefully lower the CONSOLE SUPPORT ASSEMBLY into the MONOCOLUMN.
  • Page 95 Step 10 ® Locate the POLAR RECEIVER (#16). Slide the FOAM ISOLATOR (#15) over the POLAR RECEIVER. Remove the POLAR RECEIVER JACK (G) located at the front of the MONOCOLUMN (F) near the PIVOT SHAFT (H) from the tape and plug the POLAR RECEIVER into the POLAR RECEIVER JACK.
  • Page 96 Before attempting to operate your Cross-Trainer, it is imperative that you familiarize yourself with the contents of the Operation Manual. If your Cross-Trainer does not respond as described in the OPERATION MANUAL, contact the nearest Life Fitness service center as listed in the Operation Manual.
  • Page 97: Unpacking Instructions

    Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers UNPACKAGING INSTRUCTIONS Step 1 Remove all staples from the corrugated shipping container and fold down the four sides of the base tray (A). Step 2 Lift and open the top flaps of the shipping container sleeve (B). Lift and remove the two front support posts (C).
  • Page 98: Communicating By Fax

    Simply make a copy (or copies) of the FAX sheet and fill in the necessary information. You may FAX us at any time, 24 hours a day, to either of the numbers shown. A Life Fitness service representative will process your order, or respond to your problem, as quickly as possible.
  • Page 99 CUSTOMER SUPPORT SERVICES PARTS ORDER SALE ( IF BOTH PLEASE INDICATE ) PRODUCT TROUBLESHOOTING WARRANTY NAME: CUSTOMER NO: DATE: PHONE: FAX: CONTACT NAME: METHOD OF SHIPMENT: 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO. PART NUMBER DESCRIPTION QUANTITY PRODUCT TROUBLESHOOTING PRODUCT NAME: SERIAL NO.
  • Page 100 CUSTOMER SUPPORT SERVICES 10601 W. Belmont Ave., Franklin Park IL 60131 PHONE (800) 351-3737 Toll Free or (708) 451-0036 FAX (800) 216-8893 Toll-Free or (708) 288-3702...
  • Page 101: Notes

    Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers NOTES:...

This manual is also suitable for:

91009500hr